Plastic Liner For Home Organizational Items

ABSTRACT

A home product includes a container and a plastic liner. The container includes an interior surface. The plastic liner is integrally conformed and attached to a substantial portion of the interior surface of the container to seal and protect the container. The plastic liner is conformed and attached to the container via a thermoforming or blow molding-process.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is based on and claims priority to U.S. ProvisionalPatent Application Ser. No. 60/688,598, filed Jun. 8, 2005, and U.S.Provisional Patent Application Ser. No. 60/688,562, filed Jun. 8, 2005,the contents of each of which are hereby expressly incorporated hereinby reference.

BACKGROUND OF THE INVENTION

1. Field of the Disclosure

The present disclosure is generally directed to storage containers and,more particularly, to containers with plastic liners.

2. Description of Related Art

Consumers use woven or non-woven storage containers such as baskets,storage cubes, hampers, and the like to decorate and organize theirhouses. Additionally, consumers use woven or non-woven containers astrash cans, picnic baskets, planters and the like. Typically, wovencontainers are made primarily of natural or other decorative materialsincluding but not limited to wicker, rattan, seagrass, water hyacinth,banana leaf, wood, metal, plastic and bamboo. Many consumers prefer theappearance of these woven containers to non-woven alternatives such assolid plastic, chipboard, or cardboard containers. Woven productstypically have an open pattern defining spaces or interstices due totheir woven nature. This often results in a container that is unable tohold small items. Additionally, the interiors of these containers aredifficult to clean because the woven construction creates small, hard toclean crevices that trap dust or dirt. Moreover, woven containers madeof cellulosic natural materials are often subject to water absorptionand prone to mildew growth.

Some of these woven and non-woven containers are paired with apre-formed, drop-in plastic liner made of a synthetic material such aspolyester or PVC. These liners are manufactured independently of thecontainer by various types of molding and forming operations. After theyare manufactured, the pre-formed liners are later placed inside of thecontainers in a separate assembly operation. The pre-formed plasticliners provide a cleanable and solid or non-perforated surface able tohold small items. However, the pre-formed liners do not match orintegrate with the material of the outer walls of the container and mayimpair the container's overall appearance. Additionally, tooling costsassociated with creating a pre-formed plastic liner can be expensive dueto the need for a separate liner tool unique to each shape and size ofcontainer.

Furthermore, the use of pre-formed plastic liners may createdifficulties fitting the plastic liner to a woven storage container.Specifically, woven containers have inherently variable dimensions fromcontainer to container, thereby frustrating any attempt to pre-form ageneric liner. While a pre-formed plastic liner produced fromindependent tooling may flex minimally to adapt to its container, theseliners are generally unable to accommodate significant variations inheight, width, and/or length. Additionally, these dimensional variationsmay result in a height differential between the woven container and theliner, a gap between the walls of the woven container and the liner or,conversely, an interference between the liner and container.

Other known containers are lined with fabric. Fabric liners typicallyprovide more aesthetic appeal than plastic liners. However, fabricliners typically lack the cleanability and/or water resistance of aplastic liner. Furthermore, fabric is typically less durable thanplastic. Moreover, fabric liners are generally stitched or sewn ontowoven containers or adhered to non-woven containers, both of which addcost to the manufacturing process. One known product for increasing thedurability and cleanability of fabric liners includes coated fabricliners. Coated fabric liners often include some stain resistant coatingapplied with a sprayer or roller. While these coated fabric liners mayhave some degree of improved durability and cleanability, they stillrequire the added attachment process and are not aesthetically pleasingto many consumers.

Still further known container liners include plastic film liners. Knownplastic film liners typically include plastic bag-like componentsdeposited directly into a container such as a fabric container, a wovencontainer, or any other container and fixed to a rim thereof. Thefixation is generally achieved with an adhesive or other means. Whilethese plastic film liners tend to repel most stains and are capable ofretaining small items, they are also prone to tearing and are rarelyre-usable. Additionally, such plastic film liner products are often notvery aesthetically pleasing as they do not match or integrate well withthe containers they are associated with. Accordingly, such plastic filmliners are typically used in gardening with planters, pots and othercontainers.

BRIEF DESCRIPTION OF THE DRAWINGS

Objects, features, and advantages of the present invention will becomeapparent upon reading the following description in conjunction with thedrawing figures, in which:

FIG. 1 is a perspective view of a home décor product with an integratedplastic liner constructed in accordance with the teachings of thepresent disclosure;

FIG. 2 is a cross sectional view of the container depicted in FIG. 1taken along line II-II;

FIG. 3 is a magnified cross-sectional view of a wall of the containertaken from Circle III in FIG. 2;

FIG. 4 is a magnified cross-sectional view of an alternate embodiment ofa wall of a container constructed in accordance with the teachings ofthe present invention and taken from Circle III in FIG. 2;

FIG. 5 is a magnified cross-sectional view of yet another alternateembodiment of a wall of a container constructed in accordance with theteachings of the present invention and taken from Circle III in FIG. 2;

FIG. 6 is a magnified cross-sectional view of yet another alternateembodiment of a wall of a container constructed in accordance with theteachings of the present invention and taken from Circle III in FIG. 2;

FIG. 7 is a perspective view of an alternate embodiment of a home décorproduct with an integrated plastic liner and one form of a rim componentconstructed in accordance with the teachings of the present disclosure;

FIG. 8 is a perspective view of another alternate embodiment of a homedécor product with an integrated plastic liner and another form of a rimcomponent constructed in accordance with the teachings of the presentdisclosure;

FIG. 9 is a cross sectional view of a home décor product according tothe teachings of the present disclosure and illustrating a manufacturingprocess implementing a plug and a barrier layer; and

FIG. 10 is a cross sectional view of a home décor product according tothe teachings of the present disclosure and illustrating a manufacturingprocess implementing an exterior mask.

DETAILED DESCRIPTION OF THE DISCLOSURE

Referring to FIG. 1, a home décor product 1 including a container 10with a plastic liner 12 is shown. The container 10 has a base 14 and asidewall 16 extending up from the base 14. The sidewall 16 and base 14both have interior surfaces 16 a, 14 a, respectively, and exteriorsurfaces 16 b, 14 b, respectively. In the example shown, the sidewall 16has four panels, thereby defining a container 10 with a generally squarecross-section. The cross-section of the container 10, however, may be ofany geometry or size including but not limited to square, rectangular,circular, cylindrical, partially spherical, or any other polygonal ornon-polygonal geometry and may or may not have a lid. The walls 16 andbase 14, as depicted, are constructed in a woven configuration fromnatural or other decorative materials including, but not limited to,wicker, rattan, seagrass, water hyacinth, banana leaf, wood, bamboo,metal, fabric wrapped cardboard, woven plastic or composite straps, orany combination of such materials with each other or with others. Thewalls 16 and base 14 of the disclosed container 10 may be constructed ofmultiple interwoven components as an open weave, knit, or mesh definingopenings or spaces 18 (shown in FIGS. 3-5) between its variousinterwoven components. It should be appreciated, however, that thecontainer 10 may be any foreseeable container including a solid orsubstantially solid container constructed of plastic, metal, chipboard,leather-wrapped chipboard, cardboard, fabric, or any other suitablematerial for containing items.

As stated above, the disclosed container 10 has an integrated plasticliner 12 that conforms to the interior surfaces 16 a, 14 a of the walls16 and base 14 of the container 10, as shown in FIGS. 1-6. The liner 12provides a solid impermeable layer. Additionally, in one form, the liner12 includes dimples 12 a on its interior surface and protrusions 12 b onits exterior surface, as shown in FIGS. 2-5. In the form depicted, theprotrusions 12 b at least partially extend into the spaces 18 in thewalls 16 and base 14 of the container 10, as shown in FIGS. 3-5. Theprotrusions 12 b frictionally engage the container 10 at the sides ofthe spaces 18. The shear forces resulting from this frictionalengagement mechanically interconnect and secure the liner 12 to thecontainer 10. Additionally, the plastic liner 12 may be bonded oradhered to the walls 16 and base 14 of the woven container 10, as willbe discussed in greater detail below. The liner may 12 cover as much oras little of the container 10 as desired. Furthermore, the thickness ofthe liner 12 may be selected as desired. While the home décor product 1has just been described as including a container 10 defining spaces 18,it should be appreciated that the container 10 may alternately be formedto be solid or substantially solid, as mentioned above. A solid orsubstantially solid container 10 may include a tightly woven containeror simply a container made of solid material such as plastic, metal,wood, or any other material with or without openings formed in theinterior surface thereof. FIG. 6 depicts a sidewall 16 of one such solidcontainer 10 including an interior surface 16 a with openings or pockets21. In this form, the liner 12 includes only protrusions 12 b. Theprotrusions 12 b interlock with the pockets 21 to secure the liner 12and the container 10 together. In another form, the container 10 may notinclude openings at all, but may have substantially smooth interiorsurfaces 14 a, 16 a. In such a case, the liner 12 attaches to thecontainer 10 via shear stresses or adhesive or a combination of both.

To achieve any of the above-described home décor products 1, theintegrated plastic liner 12 may be constructed through a vacuumthermoforming process for forming molten or semi-molten plastic to theshape of the container walls 16 and base 14. During this process, anest, die, or cavity is used to hold the container 10 securely in placeand to affect the container's shape if needed. Next, the molten orsemi-molten plastic sheet is placed over the opening of the containersuch that the plastic sheet is adjacent to or in contact with a rim 20of the container 10. Alternately, the molten or semi-molten plasticsheet may be directly inserted into the container 10. During the vacuumthermoforming process, the plastic sheet is then drawn via vacuumpressure, which will be discussed in greater detail below, to deform andconformingly engage the interior surfaces 14 a, 16 a of the container10. The vacuum may be created using vacuum ports located in the nest,die, or cavity used to secure the container 10. It should be understoodthat in the case of a solid container 10, the container 10 shouldinclude one or more vent holes for allowing air to escape during thevacuum process.

Upon contacting the interior container surfaces 14 a, 16 a, the moltenor semi-molten plastic sheet conforms to the geometry of the container10. In one form, the plastic inherently adheres to the interior surfaces14 a, 16 a. In other forms, the plastic may not adhesively bond with thematerial of the container 10. As mentioned above, however, the plasticliner 12 may be drawn into the spaces 18 or pockets 21 of the containerwall 16 and base 14 to create the protrusions 12 b and, if applicable,the dimples 12 a. As stated above, the protrusions 12 b mechanicallyinterconnect and secure the container 10 to the plastic liner 12 byfrictionally engaging the container 10 adjacent to the spaces 18 or inthe pockets 21, thereby preventing the liner 12 from easily slipping outof the container 10.

Alternately, as stated above and depicted in FIG. 5, the outer surfaceof the liner 12 may have an adhesive layer 22. The adhesive layer 22 maybe active or at least activated during the above-described formingprocess to adhere the liner 12 to the container 10. It should beappreciated that, in one form, the adhesive layer 22 is utilized incombination with the interlocking protrusions 12 b and spaces 18 toretain the liner 12 inside the container 10. In another form, however,the liner 12 may not include the protrusions 12 b and, therefore, theadhesive layer 22 is used as the sole device for retaining the liner 12within the container 10. Additionally, while FIG. 5 depicts the adhesivelayer 22 coating substantially the entire exterior surface of the liner12, an alternate form may include the adhesive layer 22 coating lessthan the entire exterior surface of the liner 12. For example, theadhesive layer 22 may coat the exterior surface of the liner 12 inparallel or cross-hatched bands intended to adheringly engagecorresponding parallel or cross-hatched components of the wovencontainer 10.

Additionally, if the rim 20 of the container 10 has a rough surface, amanufacturing collar may be applied to the rim 20 prior to the moltensheet being positioned on the rim 20 or inserted into the container 10.In one form, the collar may have a smooth surface for creating a sealbetween the molten plastic and itself. In another form, such a smoothsurface may not be required. Thus, the collar will assure that thevacuum is able to create a sufficient suction to draw the molten plasticsheet into engagement with the interior surfaces 14 a, 16 a of thecontainer 10, as well as into the spaces 18 or pockets 21 to create theprotrusions 12 b and, if applicable, the dimples 12 a. While the use ofsuch a collar may be beneficial in some applications, it should beappreciated that it need not be used in all applications.

In another form, the thermoforming method uses a one-piece pre-formedplastic liner. The pre-formed liner is created by heating a plasticsheet to a molten or semi-molten state and then molding the sheet usinga male pre-forming tool such as a plug. This molding may be accomplishedinside or outside of the container. After the sheet is heated, theexterior surface of the forming tool is brought into engagementtherewith. The sheet then deforms and takes the shape of the formingtool. It should be understood that the preforming tool is dimensionedsuch that it creates a plastic pre-form having external dimensionsslightly smaller than the internal dimensions of the container 10. Inthe case where the pre-form is preformed outside of the container andwhile still in its molten or semi-molten state, it is then placed intothe container 10 and thermoformed to the interior surfaces 14 a, 16 a,as described above. This method may be useful to create liners 12 forcontainers 10 with steep walls or to assist in controlling the thicknessof the liner 12 throughout the thermoforming process. It should beappreciated that while the process just described includes placing thepre-formed liner into the container 10 still in its molten orsemi-molten state, an alternate process may include allowing thepre-form to cool outside of the container 10. The cooled pre-form maythen be placed into the container 10 and reheated to the molten orsemi-molten state prior to performing the thermoforming operation.

In yet another form, a blow-molding process is used to form the liner12. Variations on this method include applying extrusion blow-molding,injection blow-molding, or injection stretch blow-molding techniques.Generally, during the application of any of these blow moldingtechniques, a fixture or adjustable table may be required to hold thecontainer 10 steady.

During the application of an extrusion blow-molding technique, anextruded parison of molten plastic with a pinched-off bottom end islowered into the container 10. Once the parison reaches the base 14 ofthe container 10, hot air is blown into the interior of the parison. Theforce created by the hot air creates a pressure that is appliedsubstantially uniformly to the interior surfaces of the parison andstretches the parison outward until it conformingly engages the interiorsurfaces 14 a, 16 a of the container 10. After the parison has stretchedto conform to the inner surfaces 14 a, 16 a of the container 10, theplastic is allowed to cool. Additionally, similar to that describedabove regarding the thermoforming vacuum process, one form of thisprocess may include placing a collar on top of the container 10 prior toapplying the hot air. In such a case, the collar may serve to provide acompressive load to the parison at the rim 20 of the container 10,thereby securing the parison in place. Additionally, the collar mayprevent or restrict the flow of the molten or semi-molten parison duringthe molding process relative to the rim 20.

Alternatively, in the case of an injection blow-molding or injectionstretch blow-molding process, an injection molded pre-form is made priorto beginning the thermoforming process. In one form, the pre-form isthen placed inside of the container 10, heated to a molten orsemi-molten state, and subsequently blown or stretched until the plasticengages and forms to the walls 14 a, 16 a of the container 10, asdescribed above. In another form, the pre-form is heated prior to beingplaced inside of the container 10.

It should be appreciated that in any of the above-described formingprocesses, an excess portion of the liner 12 may remain extending beyondthe rim 22 of the container 10 after cooling. In such a case, the excessportion should be trimmed with a trimming tool to provide a clean andaesthetically pleasing finish to the home décor product 1. In somesituations, the rim 20 of the container 10 may not provide asufficiently uniform or rigid surface along which the trimming tool maytravel for trimming the excess liner. Therefore, in one form, themanufacturing collar discussed in either of the above-describedprocesses may be used to guide the trimming tool. In such cases, thetrimming tool may travel directly along a rigid external surface of themanufacturing collar around the rim 20 of the container 10 to remove theexcess liner 12. Alternately, the manufacturing collar may include anelongated recess or groove formed on an interior surface thereof. Therecess or groove would then receive the trimming tool and guide itadjacent the rim 20 to trim the excess liner. In another alternativeform, the container 10 itself may include an elongated recess formed inits interior surface 16 a near the rim 20 for receiving and guiding thetrimming tool. In any of these cases, the liner 12 is formed to extendbeyond the rim 20 of the container 10 and is subsequently trimmed.

In yet further forms, the liner 12 may be formed with the excess servingas a top flare that is rolled or folded over the rim 20. Subsequent tocooling, the top flare is rolled over the rim 20 and adhered orotherwise secured to the container 10. Alternatively, the top flare maybe rolled or folded over the rim 20 while the liner 12 is still in asemi-molten state and then allowed to cool.

In still another form, a trim jig may be used to trim the excess liner.In such a case, the trim jig would include both a trimming tool and aguiding surface, against which the liner 12 is to be trimmed. The trimjig may be configured to engage the excess liner in slight tension,travel around the container 10 at some predetermined distance from therim 20, and simultaneously trim the liner 12.

In still yet another form, it is foreseeable that the container 10 mayinclude a foldable rim portion including, for example, the top one ortwo inches of the container 10 adjacent the rim 20. In such a case,subsequent to forming the liner 12, the rim portion is folded outward,any excess liner is trimmed with a trimming tool, and the rim portion isreturned to its original position.

It should be appreciated that the various processes described herein aremerely examples and foreseeable alternatives are intended to be withinthe scope of the present disclosure. Additionally, it should beappreciated that while the processes have been described as includingvarious sequences of actions, alternative sequences of the disclosedactions and sequences including supplemental actions not explicitlydescribed herein are intended to be within the scope of the presentdisclosure. Furthermore, while some of the above-described processeshave been disclosed as alternatives, variations and combinations thereofare also intended to be within the scope of the present disclosure.

FIGS. 7 and 8 depict alternative forms of the home décor product 1 ofthe present disclosure. The home décor products depicted in FIGS. 7 and8 may be manufactured in any of the foregoing molding processes and areidentical to the home décor product 1 depicted in FIG. 1, with theexception that they further include a rim component 24. The rimcomponent 24 is fixed to the rim 20 to provide a clean aestheticallypleasing finish to the home décor product 1. For example, as statedabove, some manufacturing processes may produce excess liner 12extending beyond the rim 20 that needs to be trimmed away. In suchcases, the component 24 serves to cover any inconsistencies or roughnessin the trimmed liner 12 and/or rim 22. In another form, the rimcomponent 24 may actually serve to increase the rigidity or durabilityor some other structural characteristic of the home décor product 1.

Specifically, FIG. 7 depicts a rim component 24 including a rim cap 26.The rim cap 26 generally includes a one-piece component constructed ofthe same general geometry of the rim 20 of the container 10. It shouldbe appreciated, however, that, as stated above, the container 10 maytake on virtually any form and therefore, so might the rim 20 and therim cap 26.

According to one form, the rim cap 26 may include a wooden cap 26 fixedto the rim 20 with an adhesive. The adhesive may be wood glue, siliconecaulk, rubber cement, epoxy, or any other type of adhesive. Accordingly,during manufacture of the home décor product 1 depicted in FIG. 7,adhesive is applied to one or both of the rim 20 and the rim cap 26after the liner 12 is thermoformed. Thereafter, the rim cap 26 is placedonto the rim 20, or vice versa, and secured in place with a clamp orsome other device until the adhesive cures, thereby fixing the twocomponents together. Although the rim cap 26 has been described as beingfixed to the rim 20 of the container 10 with an adhesive, it should beappreciated that any device for fixing the two components together isintended to be within the scope of the present disclosure. For example,the rim cap 26 may be fixed to the rim 20 with nails, threadedfasteners, double-sided adhesive strips, staples, or any other devicecapable of serving the intended purpose. Additionally, while the rim cap26 has been described as being manufactured of wood, it mayalternatively be manufactured of metal, plastic, cardboard, wicker,rattan, seagrass, water hyacinth, banana leaf, bamboo or any othermaterial capable of serving the intended purposes. Furthermore, althoughthe rim cap 26 has been disclosed as being a one-piece rim cap 26, itmay alternately be constructed of multiple pieces that are fixedindependently or dependently to the container 10. Finally, while the rimcap 26 and manufacturing collar discussed above have been described asbeing distinct components, the two may foresceably be the samecomponent.

Alternatively, as mentioned above, FIG. 8 depicts an alternate rimcomponent 24 including an internal trim component 28. The internal trimcomponent 28 serves generally the same purpose as the rim cap 26, butinstead of being attached directly to the rim 20, it is attached to theinterior surface 16 a of the sidewall 16 adjacent the rim 20. It shouldbe understood that the internal trim component 28 may be constructed ofany of the materials listed above for the rim cap 26 and may be fixed tothe container 10 by any of the devices discussed above regarding the rimcap 26. In one form, the internal trim component 28 is stapled to theinterior surface 16 a of the container 10. Furthermore, while FIG. 8depicts the internal trim component 28 as being a one-piece rimcomponent 24, it may alternatively include multiple pieces securedtogether or to the container 10 in any desirable fashion. Further yet,while the rim component 24 has been described herein as including eithera rim cap 26 or an internal trim component 28, it may foreseeablyinclude any type or configuration of a rim component 24 located adjacentto or in proximity to the rim 20 of the container to thereby increase atleast one of the aesthetic appeal of the home décor product 1, thestructural integrity of the home décor product 1, or any other feature.For example, in one alternate form, the rim component 24 may be attachedto the exterior surface 16 b of the sidewall 16 of the container 10 orany combination of attachment to the interior surface 16 a, the rim 20,and the exterior surface 16 b so as to serve the principles of thepresent disclosure.

While the liner 12 has been generally disclosed as being plastic, itshould be appreciated that, in light of the disclosure provided herein,any melt-processable material may be used to construct the liner 12. Tomaintain the aesthetic value of the container 10, however, a suitablematerial is a flexible thermoplastic elastomer which provides arubber-like appearance or a polymer that produces a transparent,semi-transparent, or opaque glass-like appearance such as poly-vinylchloride, polyester, or polystyrene. However, any material capable ofbeing thermoformed or blow-molded may be used including olefins such as,for example, polyethylene and polypropylene

Additionally, while the liner 12 has, thus far, been disclosed asincluding a single layer liner, in other forms, the liner 12 may includemultiple layers. These multiple layers may be provided in the form of,for example, co-extruded plastic sheets or thermoformable laminates. Inone example, a two-color co-extruded sheet is thermoformed to constructthe liner 12. The two-color plastic sheet has two layers of differentcolors creating a top color and a bottom color. When the plastic sheetis thermoformed to construct the liner 12, the interior surface of theliner 12 is defined by the top color of the sheet and the exteriorsurface of the liner 12 is defined by the bottom color of the sheet. Inanother example, the liner 12 includes a plastic sheet with a softmaterial top layer and hard material bottom layer. The soft material toplayer forms the interior surface of the liner 12 and the hard materialbottom layer forms the exterior surface of the liner 12. Alternately,the hard material may serve as the internal layer and the soft materialmay serve as the external layer, if desired. If this is the case, duringthermoforming, the soft external layer may deform and protrude throughthe spaces 18 in the container 10, while the hard internal layer mayremain smooth. This may further enhance the cleanability of the liner12. Further, it should be understood from the description provided thatthermoformable co-extruded materials or laminates not expresslydisclosed herein may be used to construct the liner 12.

In light of the foregoing, the disclosed plastic lined home décorproduct 1 provides a number of advantages. The liner 12 is durable andcleanable and enables a woven container to accommodate small items. Theliner 12 further provides a durable protectant for the containermaterial, whether it is woven material or non-woven material. Thisprotectant serves to extend the useful life of the home décor product,thereby increasing its consumer appeal. The disclosed inventionguarantees a tight-fitting liner, since the process inherently accountsfor dimensional variation, which is common to woven containers. Incontrast, pre-formed plastic liners such as die cut plastic ortraditional liners will not conform to the shape of the container walls.Furthermore, because such containers are often manufactured in amultitude of shapes and sizes, a multitude of unique tools or dies arerequired to manufacture the pre-formed plastic liners off-line.Producing this multitude of tools and dies can be costly andinefficient. The present disclosure eliminates the cost of producingthese tools by providing at least one process for forming a plasticliner into a container using thermoforming processes. These processes,as should be understood from the description herein, are readilyadaptable to be performed on generally any shape or size container.Additionally, use of the disclosed processes with woven or non-wovencontainers creates a novel and desirable appearance. In one form, thedisclosed home décor product using a clear plastic liner material, theprocess produced rounded protrusions that protrude from the openings inthe weave, giving the aesthetically pleasurable appearance of blownglass, as shown in FIGS. 2-5.

With reference to FIGS. 9 and 10, a yet further home décor product 101according to the principles of the present disclosure and variousprocesses for manufacturing the home décor product 101 are described.Because the product and processes disclosed in FIGS. 9 and 10 includefeatures similar to those described above, like features are assignedlike reference numerals increased by one hundred. The home décor product101 includes a container 110 and a liner 112.

The liner 112 can be created by a number of methods using a variety ofmaterials. In a first example, as shown in FIG. 9, the container liner112 is manufactured using a casting process. In this example, foam orcasting resins are poured into the woven container 110 and cured to formthe liner 112. The woven container 110 may be placed in a nest, die, orcavity to securely locate the container 110 and to affect its shape ifneeded.

A barrier layer 111 may be needed for containers constructed with a moreporous weave or from certain materials. In one example, as shown in FIG.9, the barrier layer 111 is applied to the inside of the container 110prior to the application of a resin, plastic or foam liner 112 toprevent material from seeping through the woven material. This barrier111 can be a cellulosic material with an adhesive backing, apolypropylene film, or any solid adhesive backed substrate or othermaterial that can provide a substantially foam or resin impermeablebarrier to prevent the foam or casting resins from penetrating the weaveof the container 110.

Once the container 110 is secured in the nest and any necessary barrierlayer 111 is in place, a predetermined amount of casting material ispoured into the bottom of the container 110. A plug 113, as shown inFIG. 9, is lowered into the cavity of the container and clamped in placeto hold a fixed position relative to the container 110. The plug 113 maybe made of wood, aluminum, or other suitable material and may be coatedwith a release coating such as a silicone boot or silicone spray. Theplug 113 is dimensioned to reflect the interior shape desired of theliner 112 in the container 110. The plug 113 is also dimensioned suchthat it is smaller than the inside walls of the container 110. Thedifference in size creates a cavity between the interior walls of thecontainer 110 or surfaces of the barrier layer 111 and the outer surfaceof the plug 113. The poured foam expands or the liquid resin rises tofill this cavity. The resin is then cured for a predetermined timeperiod dependant upon material selection, liner thickness, and otherfactors before the plug 113 is removed. The use of a barrier layer 111may not be needed if the weave of the container is tight enough toprevent the casting material from seeping through the interstices in thewoven container 10 or if the casting material is viscous enough suchthat it does not seep through the interstices in the woven container110.

Another method to create an integrated lined container 101 is to spraycoat the interior of the container 110 with the desired liner material.In this example, materials such as elastomers, powder coats, adhesives,urethanes or other similar materials can be sprayed to construct theliner. The interior of the container 110 is sprayed to create a networkof layers to form the liner 112 on the interior walls of the container110. This method works well for tightly-woven or solid-wall containers,and also where an initial barrier layer 111 has been applied.

For loose-weave containers, construction of a sprayed liner may requirethe use of either an outer mask 115 (shown in FIG. 10) or inner barrier111. To construct a liner 112 with an outer mask 115, the exteriorsurfaces of the walls and base of the container 110 are coated with arelease coating such as a wax label, low surface energy plastic,silicone, or other such material. Then, the interior surface of thewalls and base of the container 110 is sprayed with the liner material.Material that passes through the weave of the container 110, bonds toitself to create a solid wall, but releases from the outer mask 115 whenthe mask is removed. The mask 115 may be either physically removed, orit may be made from a soluble material and dissolved.

Alternately, to construct a sprayed coated lined container using aninner barrier 111, an inner barrier 111 is placed on the interiorsurfaces of the container 110, as shown in FIG. 9. The inner barrier 111is adhered or otherwise affixed to the interior container surfaces. Oncethe inner barrier 111 is in place the liner material is sprayed on topof the barrier 111. A layer of liner material can be sufficiently thickto cover the natural defects found in the hand-woven containers and sealthe interstices in the weave.

Numerous materials are suitable for construction of the liner 112. Inone example, liners have been constructed using a 2-part urethanematerial that is mixed immediately prior to pouring into the container110. Any other suitable urethane system can be used instead.Furthermore, other multi-part reactive materials may be used instead ofurethane. Additionally, colorants may be added to one or more of thecomponents prior to mixing to achieve a desired visual effect. Moreover,numerous other materials are suitable for construction of the linerincluding, but not limited to, rigid or flexible foam, cast flexibleurethane, rubber, cast stiff urethane, or the like.

When forming the liner 112 from urethane foam, it is desirable to selecta foam that will generate a solid, sufficiently thick skin on theinterior surface of the container 110. This will provide an easy toclean, durable, non-permeable surface. Often, the best way to create adurable non-permeable skin on the interior surface of a foam liner is touse an aluminum plug 113 with internal water cooling to achieve maximumheat transfer at the surface of the foam in contact with the plug 113.Alternatively, self-skinning foams can also be used in place of thealuminum tooling.

The interior barrier layer 111 used for containers with loose weave orfor less viscous liner materials may be made from any material that canprovide a substantially foam or resin impermeable barrier to prevent theuncured liner material from penetrating the barrier layer 111. In oneexample of an interior barrier layer 111, a cellulosic material with anadhesive backing is applied to the interior of the container 110 suchthat the adhesive surface of the barrier layer contacts the interiorsurface of the container 110 to hold the barrier layer 111 in placeprior to application of the uncured liner material. The interior barrierlayer 111 may be relatively thin in comparison to the thickness of theliner 112. The barrier layer 111 may be a polypropylene film, or anyother material that can provide a substantially foam or resinimpermeable barrier to prevent the uncured liner material frompenetrating the weave of the container 110.

The exterior mask 115 used for containers with loose weave or for lessviscous liner materials may be constructed from a low surface energymaterial that will not adhere to the liner material. The exterior mask115 may be formed using a coating such as low surface energy plastic,silicone, or other such material. Alternately, the exterior mask 115 maybe constructed from a wax coated paper or other sheet of material usedto cover the exterior surface of the container 110, as shown in FIG. 10.After the liner material has cured, the mask layer 115 may be physicallypeeled away from the woven container 110 or, in the case of a mask 115made from soluble material, may be dissolved.

The disclosed coating lined woven storage container 101 has a number ofadvantages. The disclosed liner 112 is cleanable and moisture resistantwhile economical to manufacture. Unlike separately tooled plastic linersthe disclosed manufacturing processes can easily be adapted toaccommodate different sizes and shapes of containers. Moreover, theprocess for creating the integrated liner 112 readily adapts to andaccommodates dimensional variation commonly found in woven containersand ensures a tight fit between the liner and the container wall. Thelining process is robust because the disclosed liners and methods easilyadapt to container variation in a way that pre-formed plastic liners cannot. It is also likely that this invention provides economic advantagesover the current methods, depending on the selection of liner materials.

Additionally, the disclosed processes create a tight-fitting or evenpermanent liner. In contrast, traditional plastic liners are loosefitting, removable, and often contain gaps between the liner and thesurrounding container.

Although certain lined containers, materials, and methods formanufacturing such lined containers have been described herein inaccordance with the teachings of the present disclosure, the scope ofcoverage of this patent is not limited thereto. On the contrary, thispatent covers all embodiments of the teachings of the disclosure thatfairly fall within the scope of permissible equivalents.

1. A home product, comprising: a container having an interior surface;and a plastic sheet integrally conformed and attached to a substantialportion of the interior surface of the container.
 2. The home product ofclaim 1, wherein the plastic sheet is a thermoformed plastic linerformed directly onto the interior surface of the container.
 3. The homeproduct of claim 1, wherein the container is a woven container.
 4. Thehome product of claim 1, wherein the container includes a plurality ofopenings.
 5. The home product of claim 4, wherein the plastic sheetincludes a plurality of protrusions extending at least partially intothe plurality of openings to mechanically interconnect the plastic sheetand the container.
 6. The home product of claim 5, wherein the pluralityof protrusions extend entirely through the plurality of openings.
 7. Thehome product of claim 5, wherein the plastic sheet includes a pluralityof dimples opposite the plurality of protrusions.
 8. The home product ofclaim 1, further comprising an adhesive layer disposed between theplastic sheet and the interior surface of the container to adhere theplastic sheet to the interior surface of the container.
 9. The homeproduct of claim 8, wherein the adhesive layer includes a plurality ofadhesive bands disposed between the plastic sheet and the container. 10.The home product of claim 9, wherein the plurality of bands include atleast one of a plurality of parallel bands and a plurality ofcross-hatched bands.
 11. The home product of claim 1, further comprisinga rim component fixed to a rim of the container.
 12. A home product,comprising: a woven container having an interior surface; a linerthermoformed onto the interior surface of the woven container such thatthe liner and the woven container form an integral product.
 13. The homeproduct of claim 12, wherein the liner is a plastic liner.
 14. The homeproduct of claim 12, wherein the container includes a plurality ofopenings and the liner includes a plurality of protrusions that extendat least partially into the plurality of openings to integrally connectthe liner and the container.
 15. The home product of claim 14, whereinthe liner includes a plurality of dimples opposite the plurality ofprotrusions.
 16. The home product of claim 12, further comprising anadhesive layer disposed between the liner and the container to adherethe liner to the container.
 17. The home product of claim 16, whereinthe adhesive layer includes a plurality of adhesive bands disposedbetween the liner and the container.
 18. The home product of claim 17,wherein the plurality of bands include at least one of a plurality ofparallel bands and a plurality of cross-hatched bands.
 19. The homeproduct of claim 12, further comprising a rim component fixed to a rimof the container.
 20. A method of manufacturing a lined container,comprising: heating a plastic material to at least a semi-molten state;positioning the plastic material adjacent the container; and deformingthe semi-molten plastic material into a plastic liner integrallyconformed to an interior surface of the container.
 21. The method ofclaim 20, wherein deforming the plastic material includes applying asubstantially uniform positive force to a substantial portion of theplastic material.
 22. The method of claim 21, wherein applying asubstantially uniform positive force includes performing a blow-moldingoperation on the plastic material.
 23. The method of claim 21, whereindeforming the plastic material includes extruding a plurality ofportions of the plastic material at least partially into a plurality ofopenings in the container to mechanically secure the plastic liner tothe container.
 24. The method of claim 20, wherein deforming the plasticmaterial includes applying a substantially uniform negative force to asubstantial portion of the plastic material.
 25. The method of claim 24,wherein applying a substantially uniform negative force includesperforming a vacuum thermoforming operation.
 26. The method of claim 24,wherein deforming the plastic material includes drawing a plurality ofportions of the plastic material at least partially into a plurality ofopenings in the container to mechanically secure the plastic liner tothe container.
 27. The method of claim 24, further comprising at leasttemporarily fixing a manufacturing collar to a rim of the containerprior to positioning the plastic material adjacent the container, themanufacturing collar selectively sealingly engaging a portion of theplastic material for maximizing the negative force applied to theplastic material.
 28. The method of claim 20, wherein positioning theplastic material adjacent the container includes positioning asubstantially two-dimensional plastic sheet adjacent a rim of thecontainer.
 29. The method of claim 20, wherein positioning the plasticmaterial adjacent the container includes positioning a parison withinthe container.
 30. The method of claim 20, further comprising adheringthe plastic liner to the interior surface of the container whiledeforming the plastic material.
 31. The method of claim 30, furthercomprising applying an adhesive layer to the plastic material prior todeforming the plastic material such that the adhesive layer adheringlyengages the container upon deforming the plastic material.
 32. Themethod of claim 20, further comprising trimming excess plastic from theplastic liner at a location adjacent a rim of the container subsequentto deforming the plastic material.
 33. The method of claim 20, furthercomprising fixing a rim component to the container at a location that isone of adjacent to a rim of the container and on the rim of thecontainer subsequent to deforming the plastic material.
 34. The methodof claim 20, further comprising deforming the plastic material to ageometry similar to the container prior to deforming the plasticmaterial into a plastic liner.